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CONTENTS

Factory Floor
Network Deployment
Tactical
Brief
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02. Deploying Fiber Optic Networks
03. Ethernet: It’s All About Availability
07. Recipe for a Robust Ethernet Network
12. How to Design Networks for Plant-wide Communication
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Deploying Fiber Optic Networks
As industrial networks get larger and the equipment on these networks perform more complex tasks at higher speeds,
there’s a growing need for more bandwidth.
By Terry Costlow, Contributing Editor, Automation World
M
any network managers are turning to fber optcs to meet these
demands while also gaining other benefts.
Many front ofce systems have already migrated to fber, and it’s
seeing increasing use as a central connecton for linking the plant foor
to the business network. Many companies say that it’s the best way to
ensure that there will be enough bandwidth to handle growing needs.
Cisco and Rockwell recommend using fber uplinks, saying it will
always be faster than copper.
Fiber optc connectons allow distances of up to several hundred
kilometers, whereas copper connectons only allow distances in the
100 m range. Another beneft is that it is not afected by electro-
magnetc interferences. In environments where fre or explosions
are likely, it’s safer than copper. For many, these benefts make fber
an obvious choice for backbones. Fiber and copper both have their
place in industrial applicatons. You just have to make sure to choose
the best one for the applicaton.
Where that divide occurs, however, is not simple to determine.
In many applicatons, fber is seeing litle use beyond the backbone
link between plants and ofces. It can be benefcial in demanding
applicatons like moton control and video inspecton, but copper is
also ofen a practcal soluton. Networks can be segmented so these
demanding functons are isolated, obviatng the need to shif to fber.
One of the big drawbacks for fber in the past has been its cost of
installaton. Panduit has developed techniques that eliminate many
of the steps that drive up the cost of installing fber.
“We’ve got a polymer-coated fber, released last year, that you can
just strip and clip on a connector without the gluing and polishing
that’s been required in the past,” says Dan McGrath, industrial
automaton solutons manager at Panduit (www.panduit.com).
“There’s also less waste, and you eliminate the tme of gluing and
polishing.”
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Ethernet: It’s All About Availability
The trend across the manufacturing and process industries is clear: Network users expect higher reliability,
faster speeds and wireless connectivity.
By Terry Costlow, Contributing Writer
T
he shif to Ethernet has brought many benefts, but it’s also cre-
ated new challenges for those who manage industrial networks.
Industrial users expect to not only have the bandwidth and ease of
use they see in home and commercial applicatons, but to have it all
live up to Google levels of reliability.
These high expectatons are promptng many networking teams
to reexamine their infrastructures. One of the foremost demands in
industry is that networks never shut down.
“Companies like Google, Amazon and Facebook have set very high
standards for availability,” says Ben Orchard, applicaton engineer at
Opto 22.
Network managers are responding with a number of strategies.
They’re moving to faster versions of Ethernet, altering their network-
ing architectures to provide fault tolerance, and expanding connec-
tvity with wireless links. All this is happening in conjuncton with
steps to make industrial network environments more secure.
Speed Tops the List
Leveraging Ethernet improvements, driven by commercial applica-
tons, is one of the many ratonales for employing the network in in-
dustrial applicatons. And what is perhaps the biggest advance in the
commercial Ethernet world—ever increasing speeds—is what tends
to atract a great deal of industry interest. Gbit Ethernet is beginning
to already see increased use in automaton environments, and 10
Gbit Ethernet is startng to see some acceptance.
However, there’s stll plenty of debate about where anything be-
yond 100 Mbit Ethernet is needed and where it’s superfuous. Most
observers feel that Gbit and higher architectures have a solid place as
a backbone that connects the factory foor to the front ofce, largely
because these backbones ofen also link many subnetworks together.
“We see a lot of Gbit Ethernet between switches and uplinks. It’s
mixed with 100 Mbit full duplex on the plant foor,” says Gregory
Wilcox, business development manager for networks at Rockwell
Automaton.
When and where those end devices need high-performance con-
nectons is open for discussion. Industrial devices ofen send small
amounts of data, and many of them don’t send these small data
packets very ofen. Thus, there’s litle need for high-bandwidth links
in these environments.
Others say that the economic downturn prompted many plant
managers to closely examine their requirements when they buy
new equipment. In good tmes, plant managers tend to adopt faster
networks in many areas so they will be prepared for higher require-
ments that may arise in the future. But when money’s tght, they
design for real-world demands.
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Continued
Ethernet: It’s All About Availability
“The need to chase speed has plateaued in
industrial environments,” Orchard says. “People
are fnally getng their heads around the con-
cept that 100 Mbits is adequate for 98 percent
of what they do. When money was available,
everyone wanted the fastest network. When
the economy tanked, they looked more at their
actual bandwidth requirements.”
However, some suppliers remain bullish on
faster versions, promotng both Gbit and 10
Gbit Ethernet. One of their ratonales is that as
applicatons are added down the road, 100 Mbit
Ethernet may cause botlenecks. They also note
that, as more video is used, such as with video
inspecton and security cameras, bandwidth
requirements will soar.
Rethinking Network Architectures
One of the key elements in a high-reliability
communicatons system is the network archi-
tecture. Today’s networks are laid out using
techniques that prevent downtme caused by a
single point of failure. In such layouts, problems
like broken cables or switch failures won’t cause
communicaton outages.
There are many factors that help ensure
that these ring architectures are cost-efectve
and provide both high performance and high
reliability. One is that switches are no longer
limited to standalone boxes. They’re embedded
into many diferent types of equipment.
“There’s been a move to device-level topolo-
gies with switches built into devices,” Wilcox
says. “You can go from a switch-level star to
switches on devices on a ring topology.”
Many devices now provide more than one
port, making it easy for installers to ensure that
connectons won’t be interrupted even if a cable
is disconnected or broken. These physical en-
hancements are being augmented by diferent
protocols that help reduce downtme.
“More people are using the dual Ethernet
connectons we put on our controllers,” Orchard
adds. “Redundant networks are becoming much
more common. Technologies like rapid span-
ning tree protocol are also seeing widespread
use. Fault tolerance has become much more
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cost-efectve for small and mid-sized
businesses.”
Adoptng managed switches is an-
other technique for reducing failures.
They cost a bit more than unmanaged
switches, but they bring several advan-
tages.
Though many technical issues must
be considered when high-reliability
networks are being installed or up-
graded, managers must also consider
the human side when they’re installing
equipment. Installers must be trained
to understand nuances that can cause
problems.
The Rise of Wireless
Wireless links have become an
integral part of the communicatons
infrastructure for many industrial facili-
tes, and there aren’t any signs that its
usage will subside. Cabled connectons
ofer far higher speeds, but there are
many areas where cables aren’t benef-
cial or practcal.
In recent years, tablets and smart-
phones have become another driving
force behind wireless. Many of the ear-
ly wireless networks were installed for
sensors and laptops. As the computng
power and availability of smartphones
increased, more employees started
using them in industrial areas. A grow-
ing number of companies are letng
employees link their small handheld
devices to the industrial network.
“Using your own device is really be-
coming a big deal. People aren’t having
to check their iPads or smartphones at
the door anymore,” Orchard says.
Proprietary networks designed
specifcally for industrial applicatons
were once common for wireless in-
dustrial networks. But managers who
already leverage the pricing volumes
and technical support of Ethernet are
adoptng the commercial technology
promoted by every cofee shop and
hotel—Wi-Fi. Based on the IEEE 802.11
standard family, Wi-Fi is provided in
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Ethernet: It’s All About Availability
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Continued
Ethernet: It’s All About Availability
every mobile device, and reliability has soared
as usage has spread.
Wi-Fi is taking over in many areas, but it’s
not the only alternatve for plant managers
who want to install sensors, cameras and other
equipment in their facilites. Other technologies
let managers add nodes without the cost and
trouble of running cables. Power over Ethernet
(PoE) provides a simple way for users to add
equipment in areas where adding a power cable
might be difcult, but stringing an Ethernet
cable is not a problem.
A few years ago, the PoE standard was upgrad-
ed to provide 25 W using conventonal Ethernet
connectons. Many companies have devised
techniques that boost that to 30 W, with others
pushing power capabilites up to 60 W. These
upgrades have made it viable for many indus-
trial products.
“We’re seeing a lot more interest in PoE,”
Orchard says. “The cost of switches has come
down, and people see how clean it is to have
communicaton and power on one cable. We
see even more usage as IPV6 (Internet Protocol
Version 6) makes plenty of IP addresses avail-
able.”
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Recipe for a Robust Ethernet Network
Ethernet has gained critical mass as the industrial network of choice. Automation and control engineers can dig
into some of the details of cabling, managed switches and topologies here, and leave satisfied with ways to achieve
optimum manufacturing network performance.
By Gary Mintchell, Co-Founder and Editor in Chief
T
here are two things we know about Ethernet used in manufactur-
ing and producton and one thing to be aware of for the future.
First, Ethernet has become the de facto standard network in many
industries. Its use even to the input/output (I/O) level has become
common. Second, since Ethernet is used by both enterprise and in-
dustrial systems, it has become the focal point for the age-old batle
between automaton and control engineers and informaton technol-
ogy (IT) engineers.
David McCarthy, president and CEO of TriCore, Inc. in Racine, Wis.,
says, “Industrial Networking is a whole new business area. The plant
foor, front ofce and boardroom are all converging from an informa-
ton-fow standpoint. Many of the plant foor networks in use today
are not commonly understood well by corporate IT staf. Front ofce
and enterprise networks are ofen not commonly understood well by
engineering staf. Designing a robust network soluton that satsfes
the needs of the maintenance staf, engineering, producton manag-
ers, plant managers and users of corporate IT systems—not to men-
ton system integrators and other suppliers who may be remotely
supportng a facility—requires a unique understanding of how all of
this hangs together.”
Cooperation with IT
“Historically, there has been litle convergence between manufac-
turing and enterprise in the plant network. Instead, there are mul-
tple, separate networks – one network may run feldbus protocol at
the device level, another network may run ControlNet protocol for
machine-to-machine communicatons, while a third protocol – such
as Ethernet, or a proprietary network – links the machines to data
acquisiton and storage units for reportng or archiving. Meanwhile, a
separate network, ofen an extension of the ofce Ethernet network,
is on the plant foor, enabling workstaton access to work orders and
task instructons. These networks, and the data moved across these
networks, have typically been managed and maintained by separate
groups within an organizaton on a separate infrastructure, with mini-
mal communicaton or interacton. As a result, there is less capability
for real-tme manufacturing system visibility. This increases overhead
and risks inconsistency associated with operatons status reports,
which incurs the high cost of maintaining disparate networks through
the need for stafng multple felds of expertse in the various types
of data networks, the inability to standardize on equipment and
infrastructure, and the need for complicated programming interfaces
which require constant upgrades and maintenance.
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Continued
Recipe for a Robust Ethernet Network
To gain maximum plant efciency that im-
proves Overall Equipment Efectveness (OEE),
visibility to real-tme operatonal performance
of the factory network is required. Faster start-
up and changeover tmes are needed to manage
installaton projects around scheduled shut-
downs. In additon, there is a need to reduce
the tme it takes to debug and troubleshoot
performance issues. Simplifcaton of the net-
work is especially important when personnel
resources are limited.” (See White Paper,
“Scaling the Plant Network An Approach to
Industrial Network Convergence”)
Security sticks out
Security is another stcking point with IT
people, who never believe that automaton
people take it seriously. From engineering point
of view you can implement VLANs (virtual local
area networks), Layer 3 switching, frewalls with
DMZs to combat the security issues. Think in
zones and conduits. Know the trafc between
zones and watch then alert if something not
known is seen. And (remember that) there is
never enough separaton of networks on the
control side.
So, what do we need to know about the physi-
cal media of an Ethernet TCP/IP network?
As virtualizaton, consolidaton, and conver-
gence initatves contnue to be adopted, so do
the demands placed on the physical infrastruc-
ture. Next-generaton networking architectures
deliver enhanced performance characteristcs
and capabilites to help reduce the risks associ-
ated with availability, reliability, and agility.
With today’s Ethernet speeds, especially on
the industrial foor, there is the necessity to
have a good quality data cable that can with-
stand the harsh environment. Shielding in, or
on, the cable is especially critcal. It is essental
to eliminate any interference coming from its
surroundings. If there is the requirement to
run a network cable alongside a power cable,
two things should defnitely be considered: A
shielded cable is a must, but also consider a
raceway or wire-way type of product.
Mike Hannah, manager of product develop-
ment for networks at Rockwell Automaton,
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Milwaukee, adds, “You’ve got to assure
good ground plane, cable manage-
ment, grounding, bonding, shielding
and good control panel design. Every-
one knows Ethernet, but in an indus-
trial setng, things happen like the tabs
break of the RJ45 connector. When
a machine has a fault and the opera-
tor calls maintenance, it may have just
been the cable or a loose connector.”
The optcal performance expecta-
tons for optcal channel links are speci-
fed in commercial cabling standards
such as TIA-568-C.1 and IEC 11801.
These standards specify the expected
power loss in installed fber cabling
based on fber type, number of mated
pairs of connectors deployed, and
number of fusion splices (if present).
This assures that channel links compris-
ing legacy fber types, lower bandwidth
fbers, or channels containing numer-
ous connector interfaces or splices
operate reliably. (See White Paper,
“Fiber Optc Infrastructure Applicaton
Guide Deploying a Fiber Optc Physical
Infrastructure to Support Converged
Plantwide EtherNet/IP” authored by
Panduit, Rockwell Automaton and
Cisco)
Topologies
Plantwide deployment of EtherNet/
IP requires an industrial network de-
sign methodology. Following a meth-
odology helps create a structure and
hierarchy to help maintain real-tme
network performance. In additon, it
helps enable the convergence of mult-
ple control and informaton disciplines,
including data collecton, confguraton,
diagnostcs, discrete, process, batch,
safety, tme synchronizaton, drive, mo-
ton, energy management, voice, and
video.
The Fiber Optc Infrastructure Ap-
plicaton Guide also points out that “A
highly efectve way to deploy Ether-
Net/IP solutons throughout the CPwE
architecture is to physically distribute
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Continued
Recipe for a Robust Ethernet Network
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Continued
Recipe for a Robust Ethernet Network
cabling runs using a zone cabling architecture
for all plant networks. Zone cabling enables
facility systems to be converged with Ethernet
cabling pathways as they are being designed.
This converged mult-technology backbone
comprises Category 5e/6/6A copper, optcal
fber, coaxial, RS-485, and other feldbus cabling.
These systems are converged within a common
pathway and then terminated within zone en-
closures distributed throughout the plant.
A zone cabling architecture with Stratx
switches in network zone enclosures provides a
platorm for implementng small VLANs for cell/
area zones as recommended under CPwE to im-
prove manageability and limit Layer 2 broadcast
domains. The VLAN approach allows one zone
enclosure to feed network connectons to high
priority manufacturing control system nodes as
well as lower priority connectons for printers
or data collecton, while segmentng and isolat-
ing trafc. The network segmentaton for these
VLANs is made visible using features of the
Panduit physical infrastructure, including color
coding for the patch felds and physical security
such as lock-in/blockout devices on connecton
points or physical keying solutons that prevent
inadvertent patching mistakes.
Embedded switch technology embeds popular
Layer 2 switch features directly into EtherNet/IP
devices and controller hardware to support high
performance applicatons, without the need for
additonal confguraton. This technology enables
device-level linear and ring topologies for Ether-
Net/IP applicatons. These types of devices are
found in levels 0–1 of the CPwE logical model.”
Gregory Wilcox, business development man-
ager for networks at Rockwell Automaton in
Milwaukee, says, “They’re building large fat
Layer 2 networks, but networks stll need a
structure and hierarchy. You should build do-
mains then into a Layer 3 switch where they can
see things. You use structure and hierarchy to
avoid network sprawl.”
Since Layer 3 switches use IP addresses,
setng those addresses for devices becomes
crucial to fnding them on the network. Wilcox,
again, “There are a couple of ways to set IP
addresses. One is on most devices we deploy
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Continued
Recipe for a Robust Ethernet Network
3-switch method. It could be rotary or push pin.
You set last octet number. Since 192.168.1 is the
frst three octet default, so the 3rd shif guy only
needs to look at the device, see what the setng
is, set the new one, plug in and run.”
Overall, “Ethernet is the enterprise technol-
ogy enabler. It allows interacton of control and
IT worlds,” says Peter Esparrago, Maverick plant
foor 24 of Maverick Technologies, a Columbia,
Ill.-based system integrator. “Lots of plant and
operatons guys just don’t trust IT. So they look
at Maverick (and other system integrators) as a
bridge. Regarding security, plant foor guys don’t
think they’re vulnerable, but many are becom-
ing aware. We apply same best practces, such
as defense in depth.”
Esparrago says integrators keep producton
up and running: “Corporate IT has been moni-
toring networks, but more at the WAN-Router-
Business network and stop at DMZ (if there is
one). They don’t see much when going lower,
so no one is monitoring at the control level. The
need is to monitor from device layer to business
layer. Engineers want us to monitor up to Level
2 because they don’t trust IT.”
Jason Montroy, client relatonship manager at
Maverick Technologies adds, “Ethernet net-
works allow for more remote monitoring. We
can ofer support 24/7/365. As Ethernet be-
came established, plants that had issues could
call in internal resources for trouble-shootng
and repair. Now, we’ve developed a pool of re-
sources so users can tap in and access resources
without travel.”
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How to Design Networks for Plant-wide Communication
Learn how an integrated zone cabling plan can slash network deployment time up to 75%, cut down on material and
labor costs, and allow for future expansion.
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A
s rapid advancements in networking, computng, data stor-
age and sofware capabilites increase the value of automa-
ton systems, engineers are under pressure to refresh machine and
plant-wide system designs with solutons that merge informaton
and control data. To address this challenge, validated architectures
and tested physical solutons that integrate informaton and control
systems are growing in importance.
To get connected globally into industrial operatons, users need
validated logical diagrams of the functons in the network and the in-
terface with enterprise systems. This logical networking architecture,
developed by Rockwell Automaton and its Strategic Alliance Partner
Cisco, is commonly known as the Converged Plant-wide Ethernet
(CPwE) Design and Implementaton Guide. This reference architec-
ture describes the connectvity between the enterprise and industrial
zones at a logical level.
Key within the logical architecture is the identfcaton of communi-
catons pathways from the Level 3 Site Operatons to Levels 0-2 associ-
ated within Cell/Area zones on the plant foor (see fgure on page 13).
The physical layer architecture is the infrastructure required to achieve
connectvity that addresses data throughput, environment, wiring dis-
tances and availability. A structured, engineered approach is essental
for the physical layer to ensure that investments in network distribu-
ton deliver optmum output.
Making the Right Connectons For physical architecture network
support, Layer 3 switching is typically deployed in the Level 3 Site
Operatons (industrial data center). Layer 2, or direct physical con-
nectons, are made into zone enclosures or control panels, or are
connected directly to equipment located within the Cell/Area Zone
plant foor. The physical environment of plant foor equipment and
the distance away from the control room, which acts as an interface
to the Level 3 Site Operatons, determines the characteristcs of the
cabling soluton needed. Assess environmental risks by leveraging TIA
568-C.0 “Generic Telecommunicatons Cabling for Customer Prem-
ises, Annex F: Environmental Classifcatons.”
When determining the cable soluton, consider the mechanical,
ingress, climatc and electromagnetc (MICE) conditons. This ensures
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the entre cable protecton scheme — cabinets, pathways, ground-
ing/bonding and cable selecton — is appropriate for the environ-
mental hazards present.
Traditonal structured cabling deployed in CPwE automaton net-
works involves multple horizontal copper runs all the way from the
Level 3 control room to each automaton control panel within the
Cell/Area Zone. This type of cabling is also called a “home run.” For
very small deployments, this approach works ne. But in many en-
vironments, traditonal structured cabling can mean hundreds of
lengthy copper cables that are difcult to manage, present electro
magnetc interference (EMI) susceptbility challenges, become virtu-
ally impossible to change, and are arduous to remove when comply-
ing with building codes that require removal of abandoned cable.
On the plant foor, traditonal structured cabling is routed from the
micro data center (MDC) to a control panel or zone box containing ac-
tve equipment. Alternatvely, a zone cabling approach involves a logi-
cally placed connecton point in the horizontal cable, routng it from
the MDC to actve zone boxes. Shorter cable runs then extend from the
zone box to each device in that zone (see fgure on the right).
A number of factors must be addressed when connectng the Cell/
Area Zone to the Level 3 Site Operatons control room. Users must
decide on architectures, physical media and connectvity to distrib-
ute networking that’s cost-efectve while ensuring enough fexibility,
environmental ruggedness and performance headroom to hold up to
FactoryTalk
Application
Servers
Enterprise Zone
Levels 4 and 5
Cell/Area Zone
Levels 0–2
Core
Switches
Firewall
(Standby)
Firewall
(Active)
Patch Management
Terminal Services
Application Mirror
Anti-Virus Server
Link for
Failover
Detection
HMI
Layer 2,
Industrial Ethernet
Access Switches
Cell/Area
(Ring Topology) Controller
VFD
Manufacturing Zone
Level 3
nternet
eilitaried Zone (MZ)
Stacked Layer
Distribution Switch
EtheretIP traffic
eal-time Control
Traffic segmentation, prioritiation
and management
esiliency with fast etwork
Convergence
Stacked Layer Access
Distribution Switch
etwork
Services
emote Access
Server
Layers 2 3 Access istriution
and Core etor nfrastructure
Layer 2 Access etor
nfrastructure
Site perations and Control
Multi-service etwork
outing
Security and etwork Management
Applications
Firewalls for segmentation
nified Threat Management (TM)
Authentication and authoriation
Application and Data Sharing via
replication or terminal services Access
Switch
A and Internet network
Data Centers
Enterprise Security and etwork Management
Enterprise esource Planning (EP)
Applications
Enterprise
A
Eternal DM
Firewall
Enterprise A
outers
2

Popular Confguration Drawings
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“Industrial Switch Deployment Popular Confguration Drawing”.
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current and future manufacturing needs.
Integrated Network Zone Systems
In applicatons where switching equipment is used on the plant
foor, it’s necessary to place the switch in a protectve zone enclo-
sure. The zone enclosure also houses other ancillary equipment re-
quired for the switch, such as an uninterruptble power supply (UPS),
copper and fber connectvity.
Following a zone topology allows a highly scalable and fexible
physical deployment of the CPwE architecture. Managed cabling
reduces abandoned cable and the number of home runs throughout
a facility, helping make the workplace run more efciently and safely.
An integrated network zone system is used to deploy plant-wide
EtherNet/IP™ networks and helps ensure that management and net-
work control won’t hinder the most efectve use of data available.
An integrated system incorporates all actve and passive equipment
required for deployment.
Features and benefts of using an integrated soluton system include:
- Reduced deployment tme by up to 75% with a pre-engineered,
tested and validated soluton
- Touch-safe and UL508A-rated integrated industrial and IT networks
- Reduced downtme with a robust, future-ready, reliable network
system that provides simple and easy moves, adds and changes
(MACs)
- Reduced material costs up to 30%
Long-Term Benefits
Validated logical to physical network systems can help remote users
manage productvity and proftability. With such a system, users can
access real-tme data on machine operatons and take necessary ac-
ton if pre-assigned metrics aren’t met. Plant-wide communicatons
become more efcient and future ready as users migrate proprietary
plant foor networks to a single network technology using the Ether-
Net/IP open protocol.
Whether users are updatng existng systems to meet growing in-
formaton demand needs or planning plant expansions, the amount
of development and implementaton rework tme can be costly.
Implementng validated solutons in the physical design of a network
system can reduce your deployment tme by up to 75%, ensuring
that optmum performance and reliability of your network’s physical
design are obtained. This helps maximize uptme and reduces costs
associated with problem solving and network downtme.